A deck assembly jig and method of assembly

Abstract

The application provides a deck assembly tool and an assembly method, which comprises a bottom support tool and a hoisting tool, the hoisting tool is arranged above the bottom support tool, the bottom support tool comprises a movable frame structure matched with the deck, a plurality of top supporting structures are arranged on the frame structure, the plurality of top supporting structures are matched with corresponding supporting areas on the bottom of the deck respectively to support the deck, and the hoisting tool comprises a movable lifting frame, a plurality of hoisting connecting positions are arranged on the deck, and the lifting frame is connected with each hoisting connecting position through a lifting rope. The application solves the problems that the existing yacht cannot realize the pre-assembly of the deck components and the manufacturing cycle of the whole ship is long.

Description

Technical Field

[0001] This invention relates to the field of yacht manufacturing technology, specifically to a deck assembly tooling and assembly method. Background Technology

[0002] Traditional yacht deck installation methods typically involve installing the hull components below deck first, then hoisting the deck to the hull for bonding. This method has the following problems:

[0003] First, the deck lacked an effective temporary support structure at its bottom before hoisting, making it prone to overall deformation during placement and handling. This resulted in a large positioning error after final installation on the ship's bottom, affecting assembly accuracy.

[0004] Secondly, during deck hoisting, the oblique force generated by the hoisting ropes can easily cause uneven stress on the deck, leading to deck deformation or even cracking. Once cracks appear, manual adhesive repair is required, which not only increases labor and material costs but also affects production efficiency and product quality stability.

[0005] Furthermore, under the existing installation process, fiberglass components such as deck seats, control consoles, pillars, and rigid roofs can only be installed sequentially on the deck after the bottom components are installed and the deck is attached to the bottom of the hull. This makes pre-assembly of deck modules impossible. This approach limits modular hull production, resulting in a longer overall construction cycle, lower production efficiency, and difficulty in meeting capacity demands. Summary of the Invention

[0006] To address the shortcomings of existing technologies, the first objective of this invention is to provide a deck assembly fixture. This invention solves the problems of existing yachts being unable to pre-assemble deck components and having a long overall ship manufacturing cycle.

[0007] This invention provides a deck assembly fixture, including a bottom support fixture and a lifting fixture. The lifting fixture is positioned above the bottom support fixture. The bottom support fixture includes a movable frame structure whose shape matches the deck. The frame structure has several top support structures, each of which cooperates with a corresponding area to be supported at the bottom of the deck to provide support. The lifting fixture includes a movable jack, and the deck has multiple lifting connection positions. The jack is connected to each lifting connection position via lifting ropes.

[0008] As a preferred technical solution of the present invention: the frame structure is formed by a grid-like support structure by a plurality of rectangular tubes connected in a crisscross pattern, and a plurality of the top support structures are disposed on a plurality of horizontally arranged rectangular tubes in the middle of the frame structure.

[0009] As a preferred technical solution of the present invention: the top support structure includes a plurality of connecting pipes and a plurality of support plates, each of the support plates being fixedly disposed on the top of the corresponding connecting pipe, and the bottom of each connecting pipe being fixedly connected to the frame structure.

[0010] As a preferred technical solution of the present invention: each of the top support structures forms a different support profile and corresponds to the anchor chain compartment area, cabin area, salon area and aft deck area of ​​the deck respectively, so as to form zoned support for different areas of the deck.

[0011] As a preferred embodiment of the present invention, the bottom of the frame structure is provided with several casters.

[0012] As a preferred embodiment of the present invention, hoisting connection positions are provided on the deck at the anchor chain hatch on the foredeck, the engine room hatch on the aft deck, the starboard side, and the port side.

[0013] As a preferred technical solution of the present invention: the lifting frame includes a rectangular frame structure formed by splicing several steel beams, the rectangular frame structure is provided with several rings, one end of the lifting rope is connected to the rings, and the other end is connected to the lifting connection position of the deck.

[0014] The second objective of this invention is to provide a deck assembly method, wherein any of the deck assembly fixtures described above are prefabricated, wherein the bottom support fixture serves as a dedicated carrier for the pre-assembly of the yacht deck module, and the lifting fixture serves as a hoisting fixture for the overall lifting of the deck module. The assembly method includes the following steps:

[0015] S1: Place the deck on the bottom support fixture, so that several top support structures on the frame structure cooperate with the corresponding support areas at the bottom of the deck to form zoned support for the deck, so as to maintain the overall shape and structural stability of the deck during the pre-assembly process.

[0016] S2: Foam board reinforcement structure is added at the deck ply location as a reinforcing material to improve the overall rigidity and load-bearing capacity of the deck;

[0017] S3: While keeping the deck supported by the bottom support fixture, pre-assemble the deck and install fiberglass structural components such as seats, control consoles, columns, and rigid roofs on the deck in sequence to form a deck pre-assembly module;

[0018] S4: Set up the lifting equipment above the deck, connect the lifting frame to multiple pre-set lifting connection positions on the deck through the lifting rope, lift the pre-assembled module of the deck as a whole, and transport it to the top of the hull for positioning and assembly installation with the hull.

[0019] The beneficial effects provided by this invention are as follows:

[0020] (1) The present invention sets up bottom support fixtures and hoisting fixtures in combination. The bottom support fixtures adopt a frame structure that matches the shape of the deck and use multiple top support structures to support different areas of the bottom of the deck, so that the deck can maintain a stable support state during the pre-assembly process. The pre-assembly of components such as seats, consoles, columns, and hard top covers can be completed directly on the deck, which improves the modular assembly degree of the deck, reduces the subsequent hull installation process, shortens the overall ship construction cycle, and improves production efficiency.

[0021] (2) The present invention uses a rectangular tube frame structure to replace the traditional support plate structure. It has high overall strength, is not easily deformed by moisture, has good durability and reusability, and can reduce the cost of tooling maintenance and replacement. At the same time, the bottom of the frame is equipped with moving wheels to facilitate the overall movement of the tooling and improve the convenience of on-site transportation and assembly operations.

[0022] (3) By setting up multiple top support structures and making different top support structures correspond to the anchor chain compartment area, cabin area, salon area and aft deck area of ​​the deck respectively, the present invention forms zoned support for the deck, making the deck more uniformly stressed, effectively avoiding excessive local stress and deformation during pre-assembly, and improving the structural stability of the deck during pre-assembly.

[0023] (4) This invention achieves overall hoisting of the deck module by using hoisting ropes to connect multiple hoisting connection points on the deck to the gantry, and distributes the load of the hoisting points in combination with the gantry, so that the deck is subjected to more uniform force during hoisting, effectively reducing the risk of deck deformation and cracking during hoisting, improving hoisting safety and installation accuracy, while reducing the amount of subsequent repair work and reducing labor and material costs. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a three-dimensional structural diagram of the deck assembly fixture provided in an embodiment of the present invention;

[0026] Figure 2 This is a three-dimensional structural diagram of the bottom support fixture provided in an embodiment of the present invention;

[0027] Figure 3 An axial view of the deck placed on the bottom support fixture provided in an embodiment of the present invention;

[0028] Figure 4A side view of the deck placed on the bottom support fixture provided in an embodiment of the present invention;

[0029] Figure 5 This is a schematic diagram of the foam board reinforcement structure provided in an embodiment of the present invention.

[0030] Reference numerals: 1-Bottom support fixture; 2-Lifting fixture; 3-Deck; 4-Frame structure; 5-Moving wheel; 6-Support plate; 7-Lifting frame; 8-Lifting connection position; 9-Lifting rope; 10-Rectangular tube; 11-Connecting pipe; 12-Anchor chain compartment area; 13-Compartment area; 14-Salon area; 15-Aft deck area; 16-Foredeck anchor chain hatch; 17-Aft deck engine room hatch; 18-Starboard side; 19-Port side; 20-Foam board reinforced structure. Detailed Implementation

[0031] To enable those skilled in the art to better understand the technical solutions of the present invention, preferred embodiments of the present invention are described below in conjunction with specific examples. However, it should be understood that the accompanying drawings are for illustrative purposes only and should not be construed as limiting the present invention. For better illustration of this embodiment, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable that some well-known structures and their descriptions may be omitted in the drawings for those skilled in the art. The positional relationships described in the drawings are for illustrative purposes only and should not be construed as limiting the present invention.

[0032] The present invention will be further described below with reference to the accompanying drawings and embodiments, but this should not be construed as limiting the present invention.

[0033] like Figures 1 to 4 As shown, a deck assembly fixture includes a bottom support fixture 1 and a lifting fixture 2. The lifting fixture 2 is positioned above the bottom support fixture 1. The bottom support fixture 1 includes a movable frame structure 4 whose shape matches the deck 3. The bottom of the frame structure 4 is provided with several moving wheels 5, which enable the bottom support fixture 1 to move the deck 3. The frame structure 4 is provided with several top support structures, which respectively cooperate with the corresponding areas to be supported at the bottom of the deck 3 to provide support for the deck 3. The lifting fixture 2 includes a movable jack 7, and the deck 3 is provided with multiple lifting connection positions 8. The jack 7 is connected to each lifting connection position 8 by a lifting rope 9.

[0034] The frame structure 4 is formed by a grid-like support structure formed by a number of rectangular tubes 10 connected horizontally and vertically, and a number of the top support structures are set on a number of horizontally arranged rectangular tubes 10 in the middle of the frame structure 4.

[0035] The top support structure includes several connecting pipes 11 and several support plates 6. The support plates 6 are iron plates. The several support plates 6 cooperate to form different support profiles to adapt to the structural shape of different areas of the deck 3. Each support plate 6 is fixedly installed on the top of the corresponding connecting pipe 11. The bottom of each connecting pipe 11 is fixedly connected to the frame structure 4 so as to form a top support for the deck 3 through the support plates 6.

[0036] In this embodiment, both the rectangular tube 10 and the connecting tube 11 are made of 100cm×50cm×3cm rectangular steel tubes as supporting components, resulting in a robust overall structure with good durability. After the deck 3 is placed horizontally on the bottom support fixture 1, workers can directly pre-install fiberglass products such as seats, control consoles, columns, and rigid roofs on the deck 3, thereby improving the overall structural strength of the deck 3, reducing the risk of deformation and cracking during hoisting, and also realizing the pre-assembly of deck modules, achieving modular production of the hull, shortening the construction cycle, and improving production efficiency.

[0037] Each of the aforementioned support structures forms a different support profile to adapt to the structural shape of different areas of deck 3. Each of the aforementioned support structures corresponds to the anchor chain locker area 12, compartment area 13, salon area 14, and aft deck area 15 of deck 3, respectively, to provide zoned support for different areas of deck 3. For different ship types, the support profiles formed by the support structures are also different to adapt to the shape characteristics of the bottom structure of different deck 3. The deck assembly fixtures provided in this embodiment can be designed to correspond to the deck structure of different ship types, thereby achieving stable support for deck 3.

[0038] The deck 3 is equipped with hoisting connection positions 8 on the foredeck anchor chain hatch 16, the aft deck engine room hatch 17, the starboard side 18, and the port side 19.

[0039] The jack 7 includes a rectangular frame structure 4 formed by splicing several steel beams. The size of the rectangular frame structure 4 matches the size of the deck 3. Several rings are provided on the rectangular frame structure 4. One end of the jacking rope 9 is connected to the rings, and the other end is connected to the jacking connection position 8 of the deck 3.

[0040] like Figures 1-5 As shown, the present invention also provides a deck assembly method, wherein the deck assembly fixtures described above are prefabricated, wherein the bottom support fixture serves as a special carrier for the pre-assembly of the yacht deck module, and the lifting fixture serves as the overall lifting fixture for the deck module. The assembly method includes the following steps:

[0041] S1: Place the deck 3 on the bottom support fixture 1, so that several top support structures on the frame structure 4 cooperate with the corresponding support areas at the bottom of the deck 3 to form zoned support for the deck 3, so as to maintain the overall shape and structural stability of the deck 3 during the pre-assembly process.

[0042] S2: Add foam board reinforcement structure 20 at the layup position of deck 3 as a reinforcement material to improve the overall stiffness and load-bearing capacity of deck 3;

[0043] S3: While keeping deck 3 supported by bottom support fixture 1, pre-assemble deck 3 and install fiberglass structural components such as seats, control consoles, columns, and rigid roofs on deck 3 in sequence to form a pre-assembled module of deck 3.

[0044] S4: Set the hoisting tool 2 above the deck 3, so that the jack 7 is connected to the multiple pre-set hoisting connection positions 8 of the deck 3 through the hoisting rope 9, hoist the pre-installed module of the deck 3 as a whole, and hoist it to the top of the hull to complete the positioning and assembly installation with the hull.

[0045] During the hoisting of deck 3, a hoisting fixture 2, formed by splicing multiple H-beams, was added to ensure that deck 3 was subjected to uniform stress during the hoisting process. Specifically, the hoisting fixture 2 was lifted by a crane hook, and then the hoisting fixture 2 was used to hoist deck 3. The hoisting rope 9 exerted a force on deck 3 in a basically vertical direction to minimize the possibility of deformation and cracking of deck 3 during the hoisting process, thereby reducing the time required for subsequent repair work.

[0046] Based on the description and drawings of this invention, those skilled in the art can easily manufacture or use the deck assembly tooling and assembly method of this invention, and can achieve the positive effects described in this invention.

[0047] Unless otherwise specified, in this invention, terms such as "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe orientation or positional relationships in this invention are for illustrative purposes only and should not be construed as limiting this invention. For those skilled in the art, the specific meaning of the above terms can be understood in conjunction with the accompanying drawings and according to the specific circumstances.

[0048] Unless otherwise explicitly specified and limited, the terms "set up," "connected," and "linked" in this invention should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0049] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications or equivalent changes made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. A deck assembly tooling, characterized in that: The equipment includes a bottom support fixture and a lifting fixture. The lifting fixture is positioned above the bottom support fixture. The bottom support fixture includes a movable frame structure whose shape matches the deck. The frame structure has several top support structures, which respectively cooperate with the corresponding areas to be supported at the bottom of the deck to provide support for the deck. The lifting fixture includes a movable jack, and the deck has multiple lifting connection positions. The jack is connected to each lifting connection position by a lifting rope.

2. The deck assembly fixture according to claim 1, characterized in that: The frame structure is formed by a grid-like support structure formed by the interlacing of several rectangular tubes, and several of the top support structures are set on several horizontally arranged rectangular tubes in the middle of the frame structure.

3. The deck assembly fixture according to claim 1, characterized in that: The top support structure includes several connecting pipes and several support plates. Each support plate is fixedly installed on the top of the corresponding connecting pipe, and the bottom of each connecting pipe is fixedly connected to the frame structure.

4. The deck assembly fixture according to claim 1, characterized in that: Each of the aforementioned top support structures forms a different support profile and corresponds to the anchor chain locker area, compartment area, salon area, and aft deck area of ​​the deck, respectively, so as to form zoned support for different areas of the deck.

5. The deck assembly fixture according to claim 1, characterized in that: The bottom of the frame structure is equipped with several casters.

6. The deck assembly fixture according to claim 1, characterized in that: The deck is equipped with hoisting connection points on the foredeck anchor chain hatch, aft deck engine room hatch, starboard side, and port side.

7. The deck assembly fixture according to claim 1, characterized in that: The gantry includes a rectangular frame structure formed by splicing several steel beams. Several rings are provided on the rectangular frame structure. One end of the lifting rope is connected to the ring, and the other end is connected to the lifting connection position on the deck.

8. A method for assembling a deck, characterized in that: The deck assembly fixture as described in any one of claims 1-7 is prefabricated, wherein the bottom support fixture serves as a dedicated carrier for the pre-assembly of the yacht deck module, and the lifting fixture serves as the overall lifting fixture for the deck module. The assembly method includes the following steps: S1: Place the deck on the bottom support fixture, so that several top support structures on the frame structure cooperate with the corresponding support areas at the bottom of the deck to form zoned support for the deck, so as to maintain the overall shape and structural stability of the deck during the pre-assembly process. S2: Foam board reinforcement structure is added at the deck ply location as a reinforcing material to improve the overall rigidity and load-bearing capacity of the deck; S3: While keeping the deck supported by the bottom support fixture, pre-assemble the deck and install fiberglass structural components such as seats, control consoles, columns, and rigid roofs on the deck in sequence to form a deck pre-assembly module; S4: Set up the lifting equipment above the deck, connect the lifting frame to multiple pre-set lifting connection positions on the deck through the lifting rope, lift the pre-assembled module of the deck as a whole, and transport it to the top of the hull for positioning and assembly installation with the hull.

Images